Roll-to-roll method of creating extended text labels

ABSTRACT

A roll-to-roll method of creating extended text labels includes introducing first and second web materials to a continuous, in-line, single pass, roll-to-roll press in a machine direction. In the machine direction of the press, selected graphics are printed on the first and second web materials. The first web material is selectively cut to create a foldable portion therein, with the foldable portion being in a substantially transversely folded relationship relative to the machine direction. The foldable portion of the first web material is then folded, and the first web material including the foldable portion and the second web material are joined to form a married web. The married web is then selectively cut such that at least one extended text label is created therewithin.

FIELD OF THE INVENTION

[0001] The present invention relates generally to methods of creatinglabels for product containers. The invention relates specifically to aroll-to-roll method of creating extended text or “booklet” labels forproduct containers which are labeled by roll-fed automatic labelingmachines.

BACKGROUND OF THE INVENTION

[0002] In the printing arts, and in particular in the commercial printedlabel art for labeling and decorating consumer products, there exists acontinual demand for labels and decorations which not only appeal toconsumers, but also bear ever increasing amounts of printed information.For example, labels for identification of consumer health care andpharmaceutical products are often required by governmental regulationsto describe in painstaking detail their compositions, ingredients, anduses. As new food and drug laws are passed, regulations require theinclusion of increasing amounts of information.

[0003] To provide increased printed information on labels, various formsof so-called “extended text” (or, alternatively, “extended content” or“expanded content”) labels have been proposed. One such extended textlabel type that has gained wide popularity is the booklet type label,where in its simplest form a base ply is joined to a cover ply via anadhesive coupling or “hinge” between the two plies. An example of thistype of label is disclosed in U.S. Pat. No. 5,264,265 issued toKaufmann, entitled “PEEL-BACK RE-SEALABLE MULTI-PLY LABEL”.

[0004] Aside from the aforementioned patented labels, other extendedtext labels have been proposed which comprise multiple plies, therebyproviding several booklet “pages”.

[0005] Booklet labels are commonly provided in roll form for productlabeling. The roll of labels is introduced to an automatic labelapplication machine in a container assembly line. As product containerspass downstream in the line, the booklet labels are individuallydispensed from the roll and are individually adhered to each container.

[0006] Creation of booklet labels in roll form has heretofore mainlyutilized socalled “pick-and-place” methods. In an exemplarypick-and-place method, booklets are individually created in off-line,separate press/folding operations (e.g., gate folders). The booklets socreated off-line are then loaded into a magazine of the pick-and-placeequipment. As a base ply web runs under the magazine in a lengthwise“machine direction” as known in the art, the individual booklets in themagazine are sequentially ejected onto and adhesively joined or“married” to the base ply web. This marrying of the booklet to the baseply web is commonly achieved by way of a so-called “overlaminate” thatfunctions to adhere the booklet to the base ply web, and also providesboth a booklet hinge and resealable closure.

[0007] Drawbacks of pick-and-place methods include an inability toensure color consistency and registration between separate pressoperations and variable printing processes, possibilities of mislabelingdue to incorrectly loading booklets associated with a different label“family” (e.g., mismatched barcodes), and generally increased expenseand diminished efficiency in operation. Furthermore, pick-and-placetechniques have certain web material limitations. For example, it isrecognized in the art that it is not possible to successfully create,off-line, a useable gate-folded booklet from film material. Filmmaterials have a physical “memory” which tend to maintain originalshapes and thus do not effectively maintain a folded state.

[0008] As an alternative to utilization of pick-and-place methods, aroll-to-roll method (i.e., an in-line, single pass operation) has beenemployed, where a so-called “plow folding” technique folds the webparallel to the machine direction in creation of booklets. In mostinstances, this plow folding results in a booklet label having a hingeor opening that is substantially horizontally oriented on the productcontainer, once applied thereto. However, in most cases, a verticallyoriented booklet is desired. Thus, such known plow folding methods havebeen incapable of providing material folds that are substantiallyperpendicular or transverse to the machine direction in accordance witha booklet label customer's specifications.

[0009] Therefore, there exists a need for an in-line, single pass,roll-to-roll method of creating extended text or “booklet” labels thateliminates the drawbacks of known pick-and-place and plow foldingmethods.

SUMMARY OF THE INVENTION

[0010] An object of the present invention is to provide an in-line,single pass, roll-to-roll method of creating extended text labels thatis capable of folding web material substantially transversely orperpendicularly to the machine direction.

[0011] Another object of the present invention is to provide an in-line,single pass, roll-to-roll method of creating extended text labels thatassures color consistency and registration in extended text labelproduction.

[0012] Another object of the present invention is to provide an in-lien,single pass, roll-to-roll method of creating extended text labels thatassists in preventing mislabeling.

[0013] A further object of the present invention is to decrease expenseand increase efficiency in extended text label production.

[0014] A yet further object of the present invention is to createextended text labels in an in-line, single pass, roll-to-roll method,utilizing any desired web materials such as films.

[0015] In accordance with the present invention, a roll-to-roll methodof creating extended text labels includes introducing first and secondweb materials to a continuous, in-line, single pass, roll-to-roll pressin a machine direction. In the machine direction of the press, selectedgraphics are printed on the first and second web materials. The firstweb material is selectively cut to create a foldable portion therein,with the foldable portion being in a substantially transversely foldedrelationship relative to the machine direction. The foldable portion ofthe first web material is then folded, and the first web materialincluding the foldable portion and the second web material are joined toform a married web. The married web is then selectively cut such that atleast one extended text label is created therewithin.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016]FIG. 1 is a schematic diagram of a roll-to-roll method of creatingextended text labels in accordance with the present invention.

[0017]FIG. 1a is a magnified cross-sectional view of an indicatedportion of FIG. 1.

[0018]FIG. 2 is a top view representation of a component of FIG. 1.

[0019]FIG. 3 is a schematic diagram of an alternative embodiment of aroll-to-roll method of creating extended text labels in accordance withthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0020] Referring to FIG. 1, there depicted in transparent schematicfashion is an exemplary roll-to-roll web press 100 for creating extendedtext labels.

[0021] Press 100 includes unwind units 110 a and 110 b, first and secondprinting units 120 a and 120 b, a web cutting unit 130, a foldingstation 140, and a web joining unit 150.

[0022] It is to be understood that press 100 is selectively capable ofproviding a variable number of printing units for application and dryingof pigmented inks, coatings, and adhesives. As understood by those ofordinary skill in the printing arts, the exemplary multi-unit press 100may be any suitable narrow- or wide-web press such as a flexographic,letterpress, gravure, screen, or offset press. Such presses arecommercially available from, for example, Comco International ofMilford, Ohio, or Mark Andy Inc. of St. Louis, Mo.

[0023] Specifically in FIG. 1, a first web material 160 a is supplied ina conventional roll form to press 100 at unwind unit 110 a, and in alengthwise machine direction M thereto. Concurrently, a second webmaterial 160 b is also supplied in a conventional roll form to press 100at unwind unit 110 b, also in lengthwise machine direction M. Webmaterials 160 a-b may be any suitable in-line web material such aspaper, a plastic, a foil, a so-called “unsupported” web material, apressure-sensitive adhesive laminate, or a laminate or compositeconstruction of any such materials. Additionally, as used herein, “webmaterials” may specifically also denote film, polypropylene,polyethylene, polyester, polyvinylchloride, polystyrene, and ethylenevinyl acetate.

[0024] Unwind units 110 a-b pass web materials 160 a-b, respectively, tofirst printing units 120 a and 120 b, respectively, where selectedgraphics may be printed thereon. FIG. 2 more clearly depicts, inisolation, web material 160 a with the selected graphics so printed,immediately after passing through printing unit 120 a.

[0025] Web material 160 a bearing selected graphics is then passed toweb cutting unit 130. At cutting unit 130, material 160 a may beselectively die cut and/or “slugged” (i.e., removal of material inpunch-press fashion) to create a foldable portion 162 therein.

[0026] Web material 160 a, thus bearing selected graphics and havingfoldable portion 162, is then passed to folding station 140. Foldingstation 140 operates to urge foldable portion 162 into an overalltransversely or perpendicularly folded relationship, relative to machinedirection M, with web material 160 a. Folding station 140 may be anysuitable device for effecting a fold in a web material such as, forexample, a roller, turn bar, plate, brush, air jet, vacuum, or acombination of such elements.

[0027] It should be particularly understood and appreciated that thesteps of the present invention described herethroughout provide atechnique for folding the web substantially transverse to the machinedirection. Such substantially transverse or perpendicular folding hasheretofore not been achievable while maintaining a continuous in-line,single pass, roll-to-roll process.

[0028] Materials 160 a-b then are joined to form a “married” web at webjoining unit 150. The married webs must be held in print-to-print andweb-to-web registration, such that the married webs and now folded,foldable portion 162 maintain running registration with each other asmay be required. This running registration provides proper overallregistration for final die cutting steps in creation of individualbooklet labels, as will be described.

[0029] Web joining unit 150 may be, for example, any suitable weblaminating device such as a “nip roller” as is known in the art.

[0030] Although not shown in the figure, it is to be understood thatmaterials 160 a and/or 160 b may receive a selected deposition ofadhesive for use as a hinge, closure, or both, for the individualbooklets, or for temporarily maintaining registration for the webmarrying step.

[0031] Although also not depicted in FIG. 1, married web 170 may then beintroduced to a final converting unit (such as, e.g., a die cutter) forindividual booklet label creation within married web 170, and thenre-wound into a finished product roll.

[0032] It is to be appreciated that running speeds of materials 160 aand 160 b in machine direction M may be adjusted to ensure properprint-to-print and web-to-web registration.

[0033]FIG. 3 is a schematic diagram of a press 300, showing analternative embodiment of a roll-to-roll method of creating extendedtext labels in accordance with the present invention. This exemplaryalternative embodiment of the invention provides more booklet labelpages as may be desired. It is to be noted that in FIG. 1 and in FIG. 3,similar components are identified by similar reference numerals anddescriptions.

[0034] With reference to FIG. 3, first web material 360 a is supplied ina conventional roll form to press 300 at unwind unit 110 a in lengthwisemachine direction M. Concurrently, second web material 160 b is alsosupplied as aforesaid at unwind unit 110 b, also in the direction M.

[0035] Unwind units 110 a-b pass web materials 360 a and 160 b,respectively, to first printing units 320 a and 120 b, respectively, forprinting of selected graphics thereon.

[0036] Web material 360 a bearing selected graphics and/or adhesive isthen passed to plow folding station 325, where it is plow folded ontoitself substantially parallel to the machine direction M; this will, infinished booklet label form, result in additional booklet pages relativeto the labels of FIG. 1. Plow folding station 325 may be any suitabledevice for effecting a fold in a web as aforementioned. Material 360 athen continues to unit 130 in the aforedescribed fashion.

[0037] Web material 360 a bearing selected graphics and/or adhesive, andhaving been plow folded substantially parallel to machine direction M,is then passed to web cutting unit 130, where material 360 a isselectively cut to create a foldable portion 362 therein.

[0038] Material 360 a is then passed to folding station 140. Foldingstation 140, as aforesaid, operates to urge foldable portion 362 into anoverall transverse or perpendicular folded relationship, relative todirection M, with web material 360 a.

[0039] Materials 360 a and 160 b are then joined at web joining unit150, to create a married web 170. Married web 170 is then introduced toa final converting unit (again, not depicted) for individual bookletlabel creation within married web 170, and is then re-wound into afinished product roll.

[0040] While the present invention has been particularly shown anddescribed with reference to the accompanying figures, it will beunderstood, however, that other modifications thereto are of coursepossible, all of which are intended to be within the true spirit andscope of the present invention. It should be appreciated that componentsof the invention aforedescribed may be substituted for other suitablecomponents for achieving desired similar results, or that variousaccessories may be added thereto.

[0041] It is to be particularly appreciated by the skilled artisan thatroll-to-roll booklets having a transversely or perpendicularly foldedhinge (i.e., a hinge crated by way of a simple material “fold-over”)have heretofore been possible only through off-line and pick-and-placemethods, which suffer the aforementioned drawbacks. The presentinvention, however, provides the same substantially transverse orperpendicular fold-over hinge in a continuous, in-line, single pass,roll-to-roll operation.

[0042] It is to be understood in general that any suitable alternativesor additions may be employed to provide the roll-to-roll method ofcreating extended text labels. Thus, for example, the embodiments ofFIGS. 1 and 3 may be employed in various combinations and configurationswith each other. Further, any booklet size could ultimately be provideddepending upon selected folding of the pre-married webs. Additionally,the married webs could receive an overlaminate that functions, asaforedescribed, to adhere the booklet to the base ply web, and that alsoprovides both a booklet hinge and resealable closure.

[0043] It is also to be appreciated that additional material webs couldbe introduced to press 100 in the continuous, in-line, single pass,roll-to-roll manufacturing process described herein, for provision ofmore booklet pages and/or increased booklet label output (e.g.,one-across versus multiple across label yields).

[0044] Lastly, the choice, of course, of specific components of press100 is all a matter of design choice depending upon intended uses of thepresent invention.

[0045] Accordingly, these and other various changes or modifications inform and detail of the present invention may also be made therein, againwithout departing from the true spirit and scope of the invention asdefined by the appended claims.

What is claimed is:
 1. A roll-to-roll method of creating extended textlabels, comprising the steps of: providing a first web material and asecond web material, each in a machine direction; selectively printinggraphics on said first web material and said second web material;selectively cutting said first web material to create a foldable portiontherein, said foldable portion being in a substantially transverselyfolded relationship relative to said machine direction; folding saidfoldable portion of said first web material; joining said first webmaterial including said foldable portion and said second web material toform a married web; and selectively cutting said married web such thatat least one extended text label is created thereby.
 2. The method ofclaim 1, wherein said first web material is an unsupported web material.3. The method of claim 1, wherein said second web material is apressure-sensitive adhesive web material.
 4. The method of claim 1,further comprising the step of overlaminating said married web.
 5. Aroll-to-roll method of creating extended text labels, comprising thesteps of: providing a first web material and a second web material, eachin a machine direction; selectively printing graphics on said first webmaterial and said second web material; plow folding said first web insaid machine direction; selectively cutting said first web material tocreate a foldable portion therein, said foldable portion being in asubstantially transversely folded relationship relative to said machinedirection; folding said foldable portion of said first web material;joining said first web material including said foldable portion and saidsecond web material to form a married web; and selectively cutting saidmarried web such that at least one extended text label is createdthereby.
 6. The method of claim 5, wherein said first web material is anunsupported web material.
 7. The method of claim 5, wherein said secondweb material is a pressure-sensitive adhesive web material.
 8. Themethod of claim 5, further comprising the step of overlaminating saidmarried web.
 9. A roll-to-roll method of creating extended text labels,comprising the steps of: providing a first web material and a second webmaterial, each in a machine direction; selectively printing graphics onsaid first web material and said second web material; providing aselected print-to-print and web-to-web registration, such that runningregistration is maintained relative to said web materials; selectivelyslugging said first web material to create a foldable portion therein,said foldable portion being in a substantially transversely foldedrelationship relative to said machine direction; folding said foldableportion of said first web material; joining said first web materialincluding said foldable portion and said second web material to form amarried web; and selectively cutting said married web such that at leastone extended text label is created thereby.